Enclosed Wellbore Connector with Flushing Mechanism
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Solution Overview
Problem
Existing discrete optical, electrical, and fluid wet-mate connectors are susceptible to debris and contaminants in downhole environments, leading to complex and unreliable completion equipment designs that compromise the integration and functionality of communication lines in wellbore operations.
Innovation Solution
A system and method for coupling control line connectors that protect communication lines from debris and contaminants, featuring a design with enclosed communication line connectors and a flushing mechanism to ensure reliable engagement and operation in a wellbore environment, allowing for efficient deployment and connection of multiple stage completions without exposing connectors to detrimental debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If discrete stand-alone connectors are used for wet-mate connections, then the connectors can be independently deployed and connected, but the connectors are highly susceptible to contamination by debris during the mating process
Solution Approach 1:
The patent combines the connector with the completion equipment housing to form an integrated connection system. The connector is positioned within a protected environment formed by the housing, which shields it from debris during deployment and mating operations. This integration eliminates the need for discrete stand-alone connectors while maintaining independent deployment capability through the modular completion stage design.
Solution Approach 2:
The patent introduces a protected mating environment as an intermediary between the connector and the external debris-filled wellbore environment. This protected environment, formed within the housing, acts as a mediator that allows the connector to mate with external components while being shielded from contaminants. The housing structure serves as the intermediary barrier that enables reliable connection without direct exposure to debris.
2Adaptability or versatility
If discrete connectors are used, then connection flexibility is maintained, but the geometry creates difficulty in integrating into completion equipment and limits the number of channels that can be accommodated
Solution Approach 1:
The patent merges multiple connector functions into an integrated connection system within the completion equipment housing. This integration allows multiple communication channels to be accommodated within the housing structure, increasing channel capacity while reducing the overall number of discrete components. The unified design simplifies integration into the completion equipment while maintaining connection flexibility through modular stage assembly.
Solution Approach 2:
The patent creates a universal connection system that can accommodate multiple types and numbers of communication channels within a single integrated housing design. This multi-functional connection system can handle electrical, optical, and fluid communication lines simultaneously, eliminating the need for separate discrete connectors for each channel type and simplifying the overall equipment integration.
3Reliability
If attempts are made to protect connectors from debris or provide adequate flushing, then connector protection is improved, but the completion equipment design becomes highly complex with numerous failure modes
Solution Approach 1:
The patent combines the protection function directly into the housing structure that already contains the connector, rather than adding separate protection mechanisms. The housing itself serves as the protective barrier against debris, eliminating the need for additional protective components such as separate covers, seals, or flushing systems. This integrated approach maintains connector protection while avoiding the complexity and additional failure modes associated with multiple protective subsystems.
Data Source
AI summary
A technique is provided to facilitate connection of multiple stage completions. A first completion stage is deployed at a wellbore location. Subsequently, the next completion stage is moved downhole into engagement with the first completion stage. The completion stages each have communication lines that are coupled together downhole via movement of the completion stages into engagement.